Method for laying multiple conductors in a container

ABSTRACT

A method for laying multiple conductors in a container may be provided. The method may comprise receiving the multiple conductors at a monitoring station; receiving the multiple conductors at a drive; and receiving the multiple conductors at the container.

CROSS-REFERENCE TO RELATED APPLICATIONS

The current application is a Continuation Application of and claimspriority to U.S. application Ser. No. 14/865,441 filed Sep. 25, 2015,now U.S. Pat. No. 9,796,494, which is a Continuation of U.S. applicationSer. No. 13/938,454, filed on Jul. 10, 2013, now U.S. Pat. No.9,145,219, which is a Divisional and claims priority to U.S. applicationSer. No. 13/849,018, filed on Mar. 22, 2013, now U.S. Pat. No.8,936,153, which is Continuation-In-Part of and claims priority to U.S.application Ser. No. 13/464,168, filed on May 4, 2012, which claimspriority to U.S. Provisional Application No. 61/482,326, filed on May 4,2011; U.S. Provisional Application No. 61/498,189, filed on Jun. 17,2011; U.S. Provisional Application No. 61/536,786, filed on Sep. 20,2011; U.S. Provisional Application No. 61/565,532, filed on Dec. 1,2011; and U.S. Provisional Application No. 61/606,720, filed on Mar. 5,2012, all of which are hereby incorporated by reference in theirentirety.

In addition, the current application claims priority to U.S. ProvisionalApplication No. 61/776,255, filed on Mar. 11, 2013, which is herebyincorporated by reference in its entirety.

COPYRIGHTS

All rights, including copyrights, in the material included herein arevested in and the property of the Applicants. The Applicants retain andreserve all rights in the material included herein, and grant permissionto reproduce the material only in connection with reproduction of thegranted patent and for no other purpose.

BACKGROUND

With conventional systems, at least three electricians may be needed toinstall wire. One would pull and feed the wire from a reel holder, onewould feed the wire and possible lubricate the wire into a conduit, anda third would pull the wire through the conduit. This method ofinstalling wire is very labor intensive and strenuous as the electricianpulling wire from the reel holder may have to pull hard enough toovercome then stationary inertia of multiple reels hold 50 or morepounds of wire. For example, if there are seven reels with 50 pounds ofwire on each reel, the electrician must pull with a force to overcome3,500 pounds of stationary wire.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this disclosure, illustrate various embodiments of the presentinvention. In the drawings:

FIGS. 1A, 1B, and 1C show a multiple conductor barrel assembly;

FIG. 2 shows a top view of the multiple conductor barrel assembly;

FIG. 3 shows a side view of the multiple conductor barrel assembly;

FIG. 4 shows cross-section of the multiple conductor barrel assemblyalong section line AA shown in FIG. 2;

FIG. 5 shows a barrel tap wire guide;

FIG. 6 shows an insert;

FIG. 7 shows a barrel tap wire guide;

FIG. 8 shows a method and configuration for stacking multiple conductorbarrel assemblies;

FIG. 9 shows a multiple conductor barrel having graduations;

FIG. 10 shows a label for a conductor barrel;

FIG. 11 shows a computer;

FIG. 12 shows a flowchart of a method for estimating a remaining amountof wire in a multiple conductor barrel;

FIG. 13 shows a flow chart of a method for packaging multipleconductors;

FIG. 14 shows a monitoring station;

FIG. 15 shows a guide;

FIG. 16 shows a tension equalization capstan;

FIGS. 17A and 17B show a variable speed drive system;

FIGS. 17C and 17D show a drive wheel and a pressure roller;

FIGS. 18A and 18B show a method and configuration for laying multipleconductors in a multiple conductor barrel assembly; and

FIG. 19 shows a flow chart of a method of using a container includingmultiple conductors.

DESCRIPTION

The following detailed description refers to the accompanying drawings.Wherever possible, the same reference numbers are used in the drawingsand the following description to refer to the same or similar elements.While embodiments of the invention may be described, modifications,adaptations, and other implementations are possible. For example,substitutions, additions, or modifications may be made to the elementsillustrated in the drawings, and the methods described herein may bemodified by substituting, reordering, or adding stages to the disclosedmethods. Accordingly, the following detailed description does not limitthe invention.

Consistent with embodiments of the invention, a container may beprovided. The container may comprise a first surface and a secondsurface concentric with the first surface. The first surface and thesecond surface may define a volume. The volume may house a concentriclength of multiple single conductors arranged in parallel.

With embodiments of the invention, multiple conductors may be non-bound,paralleled, cabled, twisted, non-twisted or bundled (e.g. with a binder)together and laid in a circular pattern in the container. Paralleledconductors may be conductors arranged such that they are substantiallyparallel to one another. A conductor may be any material that mayconduct electricity, light, or any signal. Examples of a conductor mayinclude copper wire, a data cable, a fiber optic cable, and aluminumwire.

An example of the container may be a barrel for housing multipleconductors. The circular pattern may be helically distributedhorizontally within the container assembly with a center core and anoutside diameter that is larger than the circular pattern effectivelyforming a horizontal layer. Moreover, each horizontal layer may belayered or stacked vertically. If the container assembly is layered andstacked, then an end user may be able to easily payoff the multipleconductors from the center of the container assembly without having toset up a reel, thus eliminating the need to lift reels and issuesassociated with paying off on reels. Additionally, a cart may be adaptedor modified to allow the container to be secured, moved, and locatedwhere needed. For example, the container may be located near or equippedwith a barrel tap wire guide that may center the conductors over thecontainer and allows it to be pulled where needed.

FIG. 1A shows a multiple conductor barrel assembly 100 (e.g., acontainer) that may be used to store, transport, and feed a cable.Multiple conductor barrel assembly 100 may comprise a first surface(e.g., an outer wall 102), a second surface (e.g., a middle wall 104),and a third surface (e.g., an inner wall 106). Outer wall 102 and middlewall 104 may form a first volume 108 (e.g., a first cavity) and middlewall 104 and inner wall 106 may form a second volume 110 (e.g., a secondcavity). Inner wall 106 may form a third volume 112 (e.g., a thirdcavity). Multiple conductor barrel assembly 100 may further comprise abottom plate 114. While FIG. 1A shows middle wall 104 and inner wall 106each having a cylindrical profile, as shown in FIG. 1B, an inner surface116 may comprise a conical profile. In addition, as shown in FIG. 1C amultiple conductor assembly 100 a may comprise bottom plate 114 andinner surface 116. The multiple conductors may be wrapped around innersurface 116.

As will be describe in greater detail below, first volume 108, secondvolume 110, and third volume 112 may be used to house and feed cables.Furthermore, items other than cables may be stored in the cavities. Forinstance, third volume 112 may include various materials such as anelectrician's tools or other supplies (e.g., wire nuts, receptacleboxes, etc.). Moreover, any number of walls and any number of cavitiesmay be used consistent with embodiments. Consistent with embodiments ofthe invention, any of the surfaces (e.g. first surface, a secondsurface, a third surface, etc.) may be solid, may contain holes, mayhave slots, may have spaces, and may form any structure (e.g. a framestructure.) The surfaces are not limited to being solid.

The cable may comprise a single conductor (e.g., THHN) or may havemultiple conductors (e.g., MC cable, parallel cables, parallelconductors, multiple sets of bound cables, insulated, un-insulated,etc.). The multiple conductors may be unbound or may be bound together.The multiple conductors may be bound together by twisting the multipleconductors together, placing a binding wire or tape around the multipleconductors, or a jacket may be placed around the multiple conductors. Inaddition, the multiple conducts may laid in the multiple conductorbarrel assembly 100 simultaneously.

FIG. 2 shows top view of multiple conductor barrel assembly 100 having afirst conductor 202 stored in first volume 108 and a second conductor204 stored in second volume 110. First conductor 202 and secondconductor 204 may be placed in multiple conductor barrel assembly 100such that they form concentric circles. For instance, FIG. 2 shows firstconductor 202 having a lay that forms counter-clockwise concentriccircles and second conductor 204 having a lay that formscounter-clockwise concentric circles. While FIG. 2 shows first conductor202 and second conductor 204 having the same lay direction, firstconductor 202 and second conductor 204 may have the opposite laydirections (i.e., first conductor 202 laying clockwise and secondconductor 204 laying counter-clockwise). As will be described in greaterdetail below with regard to FIG. 4, each set of concentric circles mayform a horizontal layer in multiple conductor barrel assembly 100.

FIG. 3 shows a side view of multiple conductor barrel assembly 100. Asshown in FIG. 3, multiple conductor barrel assembly 100 may include abarrel tap wire guide 302 that may facilitate removal of first conductor202 and second conductor 204 from multiple conductor barrel assembly100. Barrel tap wire guide 302 may comprise an opening 304 in at leastone leg 306. Leg 306 may be flexible, ridged, and adjustable. Leg 306may be fixed to a top 308 or may be rotatably connected to top 308. Top308 may be fixed to or may be rotatably connected to multiple conductorbarrel assembly 100. While FIG. 3 shows barrel tap wire guide 302 havinga curved dome type structure, barrel tap wire guide 302 may be any shapesuch as a pyramid, a conical structure, etc. Opening 304 may allow firstconductor 202 and/or second conductor 204 to exit multiple conductorbarrel assembly 100. Barrel tap wire guide 302 may also includeadditional features not shown such as a twister and devices that maybraid or bind first conductor 202 to second conductor 204.

FIG. 4 shows a cross-section of multiple conductor barrel assembly 100along section line AA shown in FIG. 2. FIG. 4 shows first conductor 202forming layers 1 through n and second conductor 204 forming layers 1through m. As shown in FIG. 4, first conductor 202 and second conductor204 may have different diameters and therefore there may be more or lesslayers formed by second conductor 204 than by first conductor 202.During use, first conductor 202 and second conductor 204 may be pulledby a user through opening 304. First conductor 202 and second conductor204 may both be fed from multiple conductor barrel assembly 100 throughopening 304. Also, first conductor 202 may be fed from multipleconductor barrel assembly 100 through opening 304 independently fromsecond conductor 204. In addition, while FIG. 4 shows first conductor202 and second conductor 204 being fed into independent sections, firstconductor 202 and second conductor 204 may be fed into the same section(e.g., first volume 108 or second volume 110). In other words, eachvolume may receive more than one conductor. Barrel tap wire guide 302may have multiple openings for first conductor 202 and second conductor204 separately.

Furthermore, while FIGS. 1 through 4 show multiple conductor barrelassembly 100 as being circular, embodiments may comprise other shapes.For example, multiple conductor barrel assembly 100 may be square,rectangular, spherical, or any other shape. For example, in variousembodiments, outer wall 102 and middle wall 104 may be circular, andinner wall 106 may be rectangular. In addition, while FIGS. 1 through 4show multiple conductor barrel assembly 100 having cavities of differingvolumes, the cavities may have the same volume. Furthermore, firstvolume 108 may be sized to hold a first particular amount of a firstconductor (e.g., 2,500 feet of 12 gauge wire) and second volume 110 maybe sized to a second particular amount of a second conductor (e.g.,2,500 feet of a 18 gauge wire). The conductors housed in the differentcavities may be of the same type. For instance, first volume 108 andsecond volume 110 may each house 5,000 feet of 12 gauge wire. Moreover,while FIGS. 1-4 show a single conductor housed in each cavity ofmultiple conductor barrel assembly 100, each cavity may house multipleconductors. For example, first volume 110 may house two parallelconductors (e.g., a 12 gauge black wire and a 12 gauge white wire) andsecond volume 112 may house a single conductor (e.g., a 12 gauge greenwire).

FIG. 5 shows another embodiment of barrel tap wire guide 302. Barrel tapwire guide 302 may comprise a plurality of legs (e.g., a first leg 502,a second leg 504, and a third leg 506) that may be connected to a collar510. Collar 510 may receive an insert 512. The connection points wherethe plurality of legs may connect to collar 510 may pivot. In addition,the plurality of legs may be adjustable in length. Furthermore, theplurality of legs may comprise clamps that may be used to connect barreltap wire guide 302 to multiple conductor barrel assembly 100. Set screwsmay be used to secure insert 512 into collar 510.

FIG. 6 shows insert 512 in more detail. Insert 512 may comprise a maleportion 602 that may mate with collar 510. Insert 512 also may comprisea neck 604 and a top portion 606. Top portion 606 may include a shapedsurface 608 that may provide conductors a smooth transition away frombarrel tap wire guide 302 as it passes up through neck 604 and out oftop portion 606. Shaped surface 608 may be curved, arc-shaped,parabolic, or any other shape that may provide a smooth transition.Shaped surface 608 may allow conductors to be pulled from multipleconductor barrel assembly 100 without damage to the conductors. Neck 604may also include a shaped surface (not shown) exposed to conductorsentering insert 512 through the bottom of neck 604. Neck 604's shapedsurface may be shaped similarly to shaped surface 608 and may allow theconductors to enter insert 512 without damage. In addition, the shapedsurfaces may allow the conductors to be pulled in any direction withoutdamage.

Insert 512 may act to hinder the conductors from falling back intomultiple conductor barrel assembly 100 when not being pulled by a user.For instance, the conductors may have a natural twist imparted upon themas they are pulled from multiple conductor barrel assembly 100. Thisnatural twist may cause portions of the conductors to rest against theinner surface of neck 604. The friction between the conductors and theinner surface may hinder the conductors from falling back into multipleconductor barrel assembly 100. Insert 512 may also include a lubricantapplying member (not show) that may apply a lubricant to the conductorsas they pass through insert 512.

FIG. 7 shows yet another embodiment of barrel tap wire guide 302 thatmay be attached to the top of multiple conductor barrel assembly 100.Barrel tap wire guide 302 may comprise a plurality of legs (e.g., afirst leg 702, a second leg 704, and a third leg 706) and a feeder ring708. Conductors from each of cavities multiple conductor barrel assembly100 may be pulled together a through feeder ring 708. Feeder ring 708may be manufactured such that portions that may contact the conductorsdo not rub against a sharp edge. In addition, feeder ring 708 may beconfigured to apply a lubricant to wires or cable being pulled throughit. Barrel tap wire guide 302 may be permanently attached or removable.

Barrel tap wire guide 302 may include a cap structure 710 that mayfacilitate removal of conductors from multiple conductor barrel assembly100. Cap structure 710 may comprise an opening 712. Cap structure 710may be flexible or may be ridged. Cap structure 710 may be fixed or maybe rotatably connected to multiple conductor barrel assembly 100. WhileFIG. 7 shows cap structure 710 having a curved structure, cap structure710 may be any shape such as a pyramid, a conical structure, etc. Capstructure 710 may also include additional features not shown such as atwister and devices that may braid or bind conductors together.

Barrel tap wire guide 302 may comprise a locking mechanism (not shown)that may comprise a choking member located internal or external tobarrel tap wire guide 302, cap structure 710, or opening 712. Thechoking member may hinder wires or cables from traveling back intomultiple conductor barrel assembly 100. For instance, during operationan electrician may pull wires or cables through cap structure 710. Thechoking member may then prevent the wires and cables from slipping backinto multiple conductor barrel assembly 100. This may prevent theelectrician from having to feed the wires and cables though barrel tapwire guide 302 every time he cuts the conductors.

Conductors used in conjunction with multiple conductor barrel assembly100, insert 512, and/or cap structure 710 may also comprise a cablehaving a jacket having a built-in lubricant (e.g., SIMPULL® cable) tolower the pulling force need to pull the wires or cables past surfacesthey may contact.

FIG. 8 shows a method 800 and configuration that may allow a multipleconductor barrel assembly 802 to be stacked on top of another multipleconductor barrel assembly 804. As show in FIG. 8, multiple conductorbarrel assembly 802 and multiple conductor barrel assembly 804 mayinclude complementary surfaces to facilitate stacking. For example, amale surface 806 and a female surface 808. During stacking, male surface806 may mate with female surface 808 to create an interlocking effectthat may help hinder multiple conductor barrel assembly 802 from slidingoff multiple conductor barrel assembly 804. When multiple conductorbarrel assembly 802 is located atop multiple conductor barrel assembly804, the weight of multiple conductor barrel assembly 802, coupled withthe interaction between male surface 806 and female surface 808, maykeep multiple conductor barrel assembly 802 from sliding off the top ofmultiple conductor barrel assembly 804.

In addition, male surface 806 and female surface 808 may include lockingmembers that may create an interlocking connection. For example, malesurface 806 may include tenons (not shown) that fit within mortises (notshown) located in female surface 808. Upon the tenons being insertedinto the mortise, multiple conductor barrel assembly 802 may be rotatedabout an axis 810 as indicated by arrow 812. This rotation may lockmultiple conductor barrel assembly 802 to multiple conductor barrelassembly 804.

FIG. 9 shows a multiple conductor barrel 900 comprising graduations 902.Multiple conductor barrel 900 may comprise an outer barrel 904 and aninner barrel 906. Inner barrel 906 may have an outer surface 908.Graduations 902 may be located on outer surface 908. In addition, outerbarrel 904 may have an inner surface 910. Graduations 902 may be locatedon inner surface 910. The graduations may be placed on an externalsurface such as a yardstick.

During manufacturing, graduations 902 may be printed directly on innersurface 910 or outer surface 908. Embodiments may also includegraduations 902 being printed on a sticker or other label (not shown)and applied to inner surface 910 or outer surface 908. Furtherembodiments may comprise multiple conductor barrel 900 being comprisedof a transparent portion, or be manufactured entirely out of atransparent material, that may allow a user to view an amount ofconductors located in multiple conductor barrel 900.

FIG. 10 shows a label 1000 that may be attached to multiple conductorbarrel 900. Label 1000 may include a designation 1002. Designation 1002may include text describing the type of cable in multiple conductorbarrel 900. For instance, designation 1002, as shown in FIG. 10, mayindicate that a cable stored in multiple conductor barrel 900 maycomprise seven 14 gauge conductors in parallel. Other information thatmay be included on label 1000 includes the number of conductors withinmultiple conductor container 900 and the amount of each contained inmultiple conductor container 900. For instance, multiple conductorcontainer 900 may contain 1,000 feet of a AWG#14 white wire and 1,500feet of a AWG#18 green wire.

Label 1000 may also include a scale 1004. Scale 1004 may provide a userwith information to estimate a remaining amount of cable in multipleconductor barrel 900. For instance, scale 1004, as shown in FIG. 10, mayindicated that for every one unit of graduation in graduations 902 theremay be 650 feet of the seven 14 gauge conductors. For example,graduations 902, as shown in FIG. 9, include 12 units, so multipleconductor barrel 900, when full, may contain 7,800 feet of cable (650feet/unit×12 units). During use an electrician may estimate he needs3,500 feet of cable for a particular job. To determine if multipleconductor barrel 900 contains enough cable for the particular job, hemay use label 1000 in conjunction with graduations 902 to determine thatif multiple conductor barrel 900 contains less than 6 units (3,500feet/650 ft/unit=5.38 units of conductors), he may not have enough cablefor the particular job.

Graduations 902 may be conductor specific or standard sizes. Forexample, multiple conductor barrel 900 may be manufactured withgraduations 902 spaced for a particular cable (e.g., a 14 gauge wire).Embodiments may also include using label 1000 to allow for multipleconductor barrel 900 to be manufactured with standard graduations. Forinstance, multiple conductor barrel 900 may be a standard barrel sizethat may be able to accept multiple types of conductor ranging from verysmall gauges to very large gauges and from a single conductor tomultiple conductors of varying gauges. Having a standard barrel withstandard graduations may make the manufacturing of multiple conductorbarrel 900 more efficient than manufacturing barrels having differentgraduations for different conductor sizes.

Label 1000 may also include other information. For instance, anestimated weight of multiple conductor barrel 900 may be included onlabel 1000. For example, label 1000 may indicate that each unit ofgraduation is approximately 100 pounds of cable. Thus, when multipleconductor barrel 900 is full of conductor (i.e., has 12 units ofconductor) it may weigh approximately 1,200 lbs. This information may beuseful when estimating shipping weights. Other information that may beincluded on label 1000 may include, for example, a lot number, modelnumber, serial number, manufacturing date, and manufacturing location.In addition, label 1000 may include a barcode 1006 that may allow a userto determine information about the contents of multiple conductor barrel900.

Furthermore, an application running on a computer 1100, shown in FIG.11, (e.g., a smartphone) may receive information that allows thecomputer calculate an amount of wire remaining in multiple conductorbarrel 900. As shown in FIG. 11, computer 1100 may include a processingunit 1112, a memory unit 1114, a display 1116, and an input unit 1118.Memory unit 1114 may include a software module 1120 and a database 1122.While executing on processing unit 1112, software module 1120 mayperform processes for determining an amount of conductor remaining inmultiple conductor barrel 900, including, for example, one or morestages included in method 1200 described below with respect to FIG. 12.

Computer 1100 (“the processor”) may be implemented using a personalcomputer, a network computer, a mainframe, a smartphone, or othersimilar computer-based system. Computer 1100 may also be configured totransmit data to a supplier or manufacturer. For instance, if there is aproblem with the wire in multiple conductor barrel 900 a user, usingcomputer 1100, may scan barcode 1006 located on label 1000 and transitthe information to the supplier of manufacturer of multiple conductorbarrel 900.

The processor may comprise any computer operating environment, such ashand-held devices, multiprocessor systems, microprocessor-based orprogrammable sender electronic devices, minicomputers, mainframecomputers, and the like. The processor may also be practiced indistributed computing environments where tasks are performed by remoteprocessing devices. Furthermore, the processor may comprise a mobileterminal, such as a smart phone, a cellular telephone, a cellulartelephone utilizing wireless application protocol (WAP), personaldigital assistant (PDA), intelligent pager, portable computer, a handheld computer, or a wireless fidelity (Wi-Fi) access point. Theaforementioned systems and devices are examples and the processor maycomprise other systems or devices.

FIG. 12 is a flow chart setting forth the general stages involved inmethod 1200 for determining an amount of wire remaining in multipleconductor barrel 900. Method 1200 may be implemented using, for example,computer 1100 as described in more detail above. Ways to implement thestages of method 1200 will be described in greater detail below.

Method 1200 may begin at starting block 1205 and proceed to stage 1210where computer 1100 may receive input. For example, after using some ofthe conductor in multiple conductor barrel 900, an electrician may inputinformation into computer 1100. For instance, the electrician may inputthe graduation displayed on label 1000 and other information such aswire size, barrel size, etc. Some of the inputs may be received bycomputer 1100 reading barcode 1006 on label 1000. In other words, theelectrician may read and input the graduation reading into computer1100. The electrician may cause computer 1100 to read barcode 1006 togather any other information needed to calculate the amount of wireremaining in multiple conductor barrel 900. As an alternative or inaddition to the graduation reading, the electrician may enter a weightof multiple conductor barrel 900 or a total resistance of the wireremaining in multiple conductor barrel 900.

From stage 1210, where computer 1100 received the input, method 1200 mayadvance to stage 1215 where computer 1100 may calculate an amount ofconductor remaining in multiple conductor barrel 900. For example,computer 1100 may use a formula stored in memory unit 1114 to calculatethe remaining amount of wire. Barcode 1006, for example, may providecomputer 1100 with information needed to retrieve information aboutmultiple conductor barrel 900 and/or about the contents of multipleconductor barrel 900 from a manufacturer via the internet, for example.After reading barcode 1006, computer 1100 may obtain a calibration scalefor graduations 902. In addition, barcode 1006 may allow computer 1100to retrieve information that may be combined with other data from theelectrician to determine an amount of conductor in multiple conductorbarrel 900. For example, after reading barcode 1006, the electrician mayinput a property such as, for example, the weight of multiple conductorbarrel 900 or the overall resistance of the conductor remaining inmultiple conductor barrel 900. For this information, computer 1100 maycalculate the amount of conductor remaining in multiple conductor barrel900.

From stage 1215, where computer 1100 calculates the remaining amount ofwire in multiple conductor barrel 900, method 1200 may advance to stage1220 where computer 1100 may display the remaining amount of wire inmultiple conductor barrel 900. In addition, computer 1100 may transmitthe remaining amount of wire in multiple conductor barrel 900 to asupplier, manufacturer, or other entity. For example, computer 1100 maytransmit the remaining amount of conductor to a supplier notifying thesupplier that the electrician may need more wire. In addition, if thereis some defect with multiple conductor barrel 900 or the conductorlocated therein, the supplier or manufacturer may be notified and theelectrician given a credit, discount, or other monetary compensation.From stage 1220, where computer 1100 may transmit data, method 1200 mayend at stage 1225.

FIG. 13 shows a flow chart for a process 1300 for packaging multipleconductors. First, in stage 1302, the multiple conductors may be fedfrom a payoff reel. The payoff reel may be part of a production line.For example, as the multiple conductors are being manufactured they maybe fed to a take-up reel. After the multiple conductors aremanufactured, the take-up reel may be stored for use in process 1300either immediately or at a later day. The take-up reel may be anycontainer suitable for storing the multiple conductors. For example, themultiple conducts may be stored in stems, barrel, reels, or as coils.

After the multiple conductors are manufactured and fed to the take-upreel, process 1300 may proceed to stage 1304 where the multiple conductsmay pass through a tension equalization fixture (shown in FIG. 14). Thetension equalization fixture may comprise a wire straightener 1406(shown in FIG. 14). The wire straightener may help remove memory ortwist in the wire that may have developed while feeding the multipleconductors from a payoff reel or a production line. For example, wirestraightener 1406 may comprise a set of rollers that the multipleconductors may pass through. The height of the rollers may be adjustedto increase or decrease the pressure on the conductors. The increase ordecrease in pressure may act to further straighten the wires.

After the multiple conductors pass through the tension equalizationfixture, process 1300 may proceed to stage 1306 where the multipleconductors may pass through a monitoring station 1400, shown in FIG. 14.Monitoring station 1400 may comprise a plurality of optical sensors1402. Plurality of optical sensors 1402 may utilize lasers and a DopplerEffect to measure a speed the conductors travel. In addition, theplurality of optical sensors 1402 may measure a length of theconductors. For example, the conductors may travel through a guide 1404(shown in greater detail in FIG. 15).

Monitoring station 1400 may allow a user to detect problems with layingthe multiple conductors in multiple conductor barrel assembly 100. Forexample, as shown in FIG. 15, a first conductor 1502 and a secondconductor 1506 may pass through one of a plurality of guide holes 1504located in guide 1402. Monitoring station 1400 may monitor the length ofeach of the conductors being fed into multiple conductor barrel assembly100. If the length or amount of each conductor being fed into multipleconductor barrel assembly 100 varies by a preset margin, process 1300may terminate or an operator may be notified. After process 1300terminates or the operator is notified, corrective measures may betaken. The preset margin may be measured as a percentage of total feetor a percentage of feet for a given feed rate. For example, firstconductor 1502 may feed at a faster rate than second conductor 1506. Toensure that roughly the same amount of first conductor 1502 and secondconductor 1506 are laid in multiple conductor barrel assembly 100, mayalert the operator when the difference between the amount of firstconductor 1502 and second conductor 1506 exceeds a certain amount.

After the multiple conductors pass through monitoring station 1400,process 1300 may proceed to stage 1308 where the multiple conductors maybe fed from monitoring station 1400 to a tension equalization capstan1600 (shown in FIG. 16). Tension equalization capstan 1600 may assistthe conductors to flow smoothly. Tension equalization capstan 1600 maypull the conductors from the payoff reel through monitoring station1400. Tension equalization capstan 1600 may assist in minimizing and/oreliminating variables such as wire bends, issues with stiff wires, andtangles.

Tension equalization capstan 1600 may be a motor driven drum that mayrotate at a constant speed. In addition, tension equalization capstan1600 may comprise multiple motor driven drums. For example, eachconductor may have its own motor driven drum that may operation atdiffering speeds than other motor driven drums. Tension equalizationcapstan 1600 may rotate at the constant speed regardless of a speedother capstans. The speed at which tension equalization capstan 1600rotates may be set higher than a highest speed the multiple conductorsmay be fed at. The highest speed may be the actual speed the multipleconductors are fed to multiple conductor barrel 100 or it may be ananticipated highest speed.

During operation, the multiple conductors may be in a loosely or tightlywrapped around drum 1602. For example, if the multiple conductors arebeing pulled, they may be wrapped around drum 1602 tighter than if theywere not being pulled. Drum 1602 may be rotating in the direction themultiple cables are traveling. If there is no tension on the multipleconductors, drum 1602 may rotate without moving the multiple conductorsmoving. This rotation without the multiple conductors moving mayfacilitate a smooth flow of wire between the tension equalizationcapstan and multiple conductor barrel assembly 100.

Drum 1602 may have a finely machined finish. The finely machined finishmay be located on the exterior of drum 1602 where the multipleconductors contact drum 1602. The finely machined finish may allow thedrum to rotate freely when no or little tension is on the multipleconductors. The finely machined finish may also allow the drum to feedthe multiple conductors. As shown in FIG. 16, drum 1602 may alsocomprise a plurality of groves 1604. Groves 1604 may assist in keepingthe multiple conductors from becoming tangled or crossing one another.

Tension equalization capstan 1600 may also comprise a guide 1606, whichmay be similar to guide 1402 shown in FIG. 15, having a plurality ofholes. Each hole may receive one of the multiple conductors. Guide 1606may assist in keeping the multiple conductors separate and may helphinder the multiple conductors from drifting and becoming tangled.

From stage 1308 where the multiple conductors may be fed to tensionequalization capstan 1600, process 1300 may proceed to stage 1310 wherea variable speed drive system 1700 (shown in FIGS. 17A and 17B) maypackage the multiple conductors.

During process 1300, each of the multiple conductors may be fed fromtension equalization capstan 1600 to variable speed drive system 1700.Variable speed drive system 1700 may comprise a drive wheel 1702, apressure roller 1704, a feed channel 1706, and a feed tube 1708. Duringoperation, the multiple conductors may be fed through drive wheel 1702and pressure roller 1704. The rotation drive wheel 1702 may pull themultiple conductors and cause them to tighten around drum 1602 and maycause the multiple conductors to move in unison. The pressure applied bypressure roller 1704 to drive wheel 1702 may assist drive wheel 1702 ingripping the multiple conductors. For example, if the multipleconductors have lubricated insulation, pressure may be applied viapressure roller 1704 to increase the friction between drive wheel 1702and the lubricated insulation. This increased friction may assist inminimizing slippage between drive wheel and the multiple conductors.

Pressure roller 1704 may apply pressure via a hydraulic, pneumatic, orelectric actuator. Pressure roller 1704 may comprise grooves orprotrusions (1710 in FIG. 17B) that may mate with correspondingprotrusion or grooves (1712 in FIG. 17B) in drive wheel 1702 to assistin increasing a contact surface area. The increased contact surface areamay assist in minimizing slippage when a lubricated wire is used.

The multiple conductors may exit drive wheel 1702 and enter feed channel1706. From feed channel 1706, the multiple conductors may enter feedtube 1708 where they may feed into multiple conductor barrel assembly100. Feed channel 1706 may assist in orienting the multiple conductors.The orientation may allow the multiple conductors to be laid in a mannersuch that any memory or twist in the multiple conductors may entermultiple conductor container assembly 100 in coincide with one another.In other words feed channel 1706 may cause the multiple conductors tohave a singular memory. A singular memory may comprise any memory ortwist in each of the conductors coinciding with any memory or twist ofother conductors.

FIG. 17C shows an embodiment of drive wheel 1702 and pressure roller1704. As shown in FIG. 17C, drive wheel 1702 may comprise multiplesections (e.g., a first section 1714, a second section 1716, a thirdsection 1718, and a fourth section 1720). The multiple sections may beof equal diameter. Pressure roller 1704 may comprise multiple sections(e.g., a fifth section 1722, a sixth section 1724, a seventh section1726, and an eighth section 1728. The sections of pressure roller 1704may comprise tenons 1730. Drive wheel 1702 may comprise grooves 1732.During operation, tenons 1730 may nestle within grooves 1732. Thetolerances between grooves 1732 and tenons 1730 may be such that duringoperation the conductors sandwiched between the pressure roller 1704 anddrive wheel 1702 have very little room to move vertically or laterally.The tight tolerances may also help to prevent damage to the conductorsand any sheathing that may cover the conductors. In addition, the tighttolerances help to ensure that a consistent length of conductor is beingfed with each revolution of the drive wheel 1702.

Multiple conductors (e.g., a first conductor 1734, a second conductor1736, a third conductor 1738, and a fourth conductor 1740) may passbetween drive wheel 1702 and pressure roller 1704. During installationof the multiple conductors into container 100, drive wheel 1702 mayrotate at a predetermined speed. Depending on the diameter of drivewheel 1702, each revolution of drive wheel 1702 may advance a givenamount to the multiple conductors. For example, the multiple sections ofdrive wheel 1702 may have a diameter of six-inches. For a six-inchdiameter, the drive wheel may advance the multiple conductorsapproximately 19 inches per revolution. Groves 1732 and tenons 1730 maybe coated with a material (e.g., rubber) to help increase frictionbetween drive wheel 102 and the multiple conductors.

The multiple sections of drive wheel 1702 may rotate in unison or theymay rotate independently of each other. For example, the multiplesections of drive wheel 1702 may share a common axel 1742. Onerevolution of axel 1742 may cause each of the multiple sections torotate one revolution. Each of the multiple sections may also rotate onrespective independent axes (not shown). For example, first section 1714may be connected to a first axis (not shown) that may be driven by afirst motor (not shown), second sections 1716 may be connected to asecond axis (not shown) that may be driven by a second motor (notshown), etc. Because the multiple sections are independent of eachother, the speed of each may be increased or decreased without affectingthe speed of others. In addition to a single drive wheel, embodimentsmay comprise multiple drive wheels and multiple pressure rollers.

FIG. 17D shows an embodiment of drive wheel 1702 and pressure roller1704. As shown in FIG. 17D, drive wheel 1702 may comprise multiplesections (e.g., first section 1714, second section 1716, third section1718, and fourth section 1720). The multiple sections may be of unequaldiameter. For example, first section 1714 may be six-inches in diameterand fourth section 1720 may be three-inches in diameter. Pressure roller1704 may comprise multiple sections (e.g., fifth section 1722, sixthsection 1724, seventh section 1726, and eighth section 1728. Thesections of pressure roller 1704 may comprise tenons 1730. Drive wheel1702 may comprise grooves 1732. During operation tenons 1730 may nestlewithin grooves 1732.

Multiple conductors (e.g., first conductor 1734, second conductor 1736,third conductor 1738, and fourth conductor 1740) may pass between drivewheel 1702 and pressure roller 1704. During installation of the multipleconductors into container 100, drive wheel 1702 may rotate at apredetermined speed. Depending on the diameter of each section of drivewheel 1702, each revolution of drive wheel 1702 may advance a givenamount to the multiple conductors. For example, first section 1714 ofdrive wheel 1702 may have a diameter of six-inches and fourth section ofdrive wheel 1702 may have a diameter of three-inches. For the six-inchdiameter first section 1714 may advance first conductor 1734approximately 19 inches per revolution and the three-inch diameterfourth section 1720 may advance fourth conductor 1740 approximately 9.5inches per revolution. Grooves 1732 and tenons 1730 may be coated with amaterial (e.g., rubber) to help increase friction between drive wheel102 and the multiple conductors.

The multiple sections of drive wheel 1702 may rotate in unison or theymay rotate independently of each other. For example, the multiplesections of drive wheel 1702 may share a common axel 1742. Onerevolution of axel 1742 may cause each of the multiple sections torotate one revolution. Each of the multiple sections may also rotate onrespective independent axes (not shown). For example, first section 1714may be connected to a first axis (not shown) that may be driven by afirst motor (not shown), second sections 1716 may be connected to asecond axis (not shown) that may be driven by a second motor (notshown), etc. Because the multiple sections are independent of eachother, the speed of each may be increased or decreased without affectingthe speed of others. In addition to a single drive wheel, embodimentsmay comprise multiple drive wheels and multiple pressure rollers.

FIGS. 18A and 18B show a method and configuration that may beimplemented to lay multiple conductors in multiple conductor barrelassembly 100 with first conductor 202 and second conductor 204. In theembodiment shown in FIG. 18A, multiple conductor barrel assembly 100 maybe located proximate feed tube 1708. Feed tube 1708 may feed firstconductor 202 and second conductor 204 at a constant or variable speedas indicated by arrow 1804. While first conductor 202 and secondconductor 204 is being fed from feed tube 1708, multiple conductorbarrel assembly 100 may be rotated about an axis 1806 as indicated byarrow 1808. During loading of multiple conductor barrel assembly 100with first conductor 202 and second conductor 204, the rotational speedof multiple conductor barrel assembly 100 may be constant or variable.

Consistent with embodiments of the invention, feed tube 1708 may feedfirst conductor 202 and second conductor 204 at a constant speed andmultiple conductor barrel assembly 100 may rotate at a constant speed.In addition, feed tube 1708 may feed first conductor 202 and secondconductor 204 at a variable speed and multiple conductor barrel assembly100 may rotate at a constant speed. Furthermore, feed tube 1708 may feedfirst conductor 202 and second conductor 204 at a variable speed andmultiple conductor barrel assembly 100 may rotate at a constant speed.Moreover, consistent with embodiments of the invention, feed tube 1708may feed first conductor 202 and second conductor 204 at a variablespeed and barrel assembly 100 may rotate at a variable speed. By varyingthe feed first conductor 202 and second conductor 204 and/or the speedat which multiple conductor barrel assembly 100, the placement locationof first conductor 202 and second conductor 204 in multiple conductorbarrel assembly 100 may be controlled.

Also, during manufacturing, feed tube 1708 may be stationary or it too,may rotate. For example, consistent with embodiments of the invention,both feed tube 1708 and multiple conductor barrel assembly 100 (asindicated in FIG. 18A by assembly 1810) may rotate about axis 1812 asindicated by arrow 1814. While assembly 1810 may be rotating about axis1812, barrel assembly 100 may or may not be rotating about axis 1806 asdescribed above. In this way, the placement location of first conductor202 and second conductor 204 in multiple conductor barrel assembly 100may be controlled. In addition and as described above the feed rate forfeed tube 1708 may be constant or variable and the rotation of multipleconductor barrel assembly 100 about axis 1806 may be constant orvariable.

In addition, while FIGS. 18A and 18B show two cables (first conductor202 and second conductor 204) being installed in multiple conductorbarrel assembly 100, there may be a second cable feeding assembly thatmay feed a third cable or feed tube 1708 may feed a third cable. Forinstance, FIG. 2 shows first conductor 202 and second conductor 204located in multiple conductor barrel assembly 100. To achieve thisconfiguration, there may be a second feed tube that lays the thirdconductor simultaneously with first conductor 202 and second conductor204. Or each cable located in multiple conductor barrel assembly 100 maybe laid down in separate stages. For example, first conductor 202 may beloaded in barrel assembly 100 at a first loading stage and secondconductor 204 may be loaded in multiple conductor barrel assembly 100 ata second loading stage.

FIG. 19 shows a flow chart for a method 1900 for using multipleconductor container assembly 100. In other words, FIG. 19 shows a flowchart for method 1900 where a non-rotating container is use to payoffmultiple conductors. Method 1900 may begin at stage 1902 where multipleconductor container assembly 100 may be positioned at a job site. Forexample, multiple conductor container assembly 100 may be placed in adesired location using a cart as described in U.S. Patent Applicationhaving Ser. No. 61/536,786, which is hereby incorporated by reference inits entirety.

After multiple conductor container assembly 100 is located at the jobsite, method 1900 may proceed to stage 1904 where a user may set upmultiple conductor container assembly 100. For example, the user mayfeed first conductor 202 and second conductor 204 from multipleconductor container assembly 100 through container tap wire guide 302.From container tap wire guide 302 the user may connect the multipleconductors to a pulling apparatus (e.g., electrician's fish tape).

After setting up multiple conductor container assembly 100, the user maypayoff the multiple conductors from multiple conductor containerassembly 100. For example, the user may pull the fish tape through aconduit. As the fish tape is pulled through the conduit, the multipleconductors may payoff from multiple conductor container assembly 100 andbe pulled through the conduit.

Embodiments, for example, may be implemented as a computer process(method), a computing system, or as an article of manufacture, such as acomputer program product or computer readable media. The computerprogram product may be a computer storage media readable by a computersystem and encoding a computer program of instructions for executing acomputer process. The computer program product may also be a propagatedsignal on a carrier readable by a computing system and encoding acomputer program of instructions for executing a computer process.Accordingly, the present invention may be embodied in hardware and/or insoftware (including firmware, resident software, micro-code, etc.). Inother words, embodiments of the present invention may take the form of acomputer program product on a computer-usable or computer-readablestorage medium having computer-usable or computer-readable program codeembodied in the medium for use by or in connection with an instructionexecution system. A computer-usable or computer-readable medium may beany medium that can contain, store, communicate, propagate, or transportthe program for use by or in connection with the instruction executionsystem, apparatus, or device.

The computer-usable or computer-readable medium may be, for example butnot limited to, an electronic, magnetic, optical, electromagnetic,infrared, or semiconductor system, apparatus, device, or propagationmedium. More specific computer-readable medium examples (anon-exhaustive list), the computer-readable medium may include thefollowing: an electrical connection having one or more wires, a portablecomputer diskette, a random access memory (RAM), a read-only memory(ROM), an erasable programmable read-only memory (EPROM or Flashmemory), an optical fiber, and a portable compact disc read-only memory(CD-ROM). Note that the computer-usable or computer-readable mediumcould even be paper or another suitable medium upon which the program isprinted, as the program can be electronically captured, via, forinstance, optical scanning of the paper or other medium, then compiled,interpreted, or otherwise processed in a suitable manner, if necessary,and then stored in a computer memory.

While certain embodiments have been described, other embodiments mayexist. Furthermore, although embodiments have been described as beingassociated with data stored in memory and other storage mediums, datacan also be stored on or read from other types of computer-readablemedia, such as secondary storage devices, like hard disks, floppy disks,or a CD-ROM, a carrier wave from the Internet, or other forms of RAM orROM. Further, the disclosed methods' stages may be modified in anymanner, including by reordering stages and/or inserting or deletingstages, without departing from the invention.

Embodiments, for example, are described above with reference to blockdiagrams and/or operational illustrations of methods, systems, andcomputer program products according to embodiments of the invention. Thefunctions/acts noted in the blocks may occur out of the order as shownin any flowchart. For example, two blocks shown in succession may infact be executed substantially concurrently or the blocks may sometimesbe executed in the reverse order, depending upon the functionality/actsinvolved.

Both the foregoing general description and the following detaileddescription are examples and explanatory only, and should not beconsidered to restrict the invention's scope, as described and claimed.Further, features and/or variations may be provided in addition to thoseset forth herein. For example, embodiments may be directed to variousfeature combinations and sub-combinations described herein.

While certain embodiments of the invention have been described, otherembodiments may exist. While the specification includes examples, theinvention's scope is indicated by the following claims. Furthermore,while the specification has been described in language specific tostructural features and/or methodological acts, the claims are notlimited to the features or acts described above. Rather, the specificfeatures and acts described above are disclosed as examples forembodiments of the invention.

What is claimed is:
 1. A method for laying multiple conductors in acontainer, the method comprising: receiving the multiple conductors fromat least one payoff reel at a monitoring station configured to monitor alength of each of the multiple conductors; passing the multipleconductors through a tension equalization capstan; receiving themultiple conductors at a variable speed drive; and receiving themultiple conductors at the container.
 2. The method of claim 1, whereinreceiving the multiple conductors at the monitoring station comprisesmonitoring a length of each of the multiple conductors individuallypassing through the monitoring station with an optical scanner.
 3. Themethod of claim 2 further comprising: detecting, via the opticalscanner, a variation in the length of each of the multiple conductorspassing through the monitoring station; and altering an operation whenthe variation exceeds a predetermined amount.
 4. The method of claim 1,wherein receiving the multiple conductors at the container comprisespassing the multiple conductors through a feed tube located between thevariable speed drive and the container.
 5. The method of claim 1,wherein receiving the multiple conductors at the variable speed drivecomprises passing the multiple conductors between a drive wheel and apressure roller.
 6. The method of claim 1, wherein the multipleconductors are unbound.
 7. The method of claim 1, wherein at least oneof the multiple conductors comprises a conductor comprising aninsulation or jacket comprising a lubricant.
 8. The method of claim 1,further comprising removing the multiple conductor from at least onepayoff reel, wherein removing the multiple conductors from at least onepayoff reel comprises removing each conductor from a separate payoffreel.
 9. The method of claim 1, further comprising monitoring a feedingcharacteristic of at least one of the multiple conductors.
 10. Themethod of claim 9, further comprising adjusting the feedingcharacteristic of at least one of the multiple conductors.
 11. Themethod of claim 10, wherein adjusting the feeding characteristic of theat least one of the multiple conductors comprises decreasing orincreasing the speed of grooved interlocking rollers to decrease orincrease the speed at least one of the multiple conductors travels. 12.The method of claim 10, wherein adjusting the feeding characteristic ofat least one of the multiple conductors when the feeding characteristicof the at least one of the multiple conductors varies comprisesadjusting the feeding characteristic of the at least one of the multipleconductors when the feeding characteristic of the at least one of themultiple conductors varies by a predetermined amount, and wherein layingthe multiple conductors into the container comprises laying a samelength of each of the multiple conductors into the container.